Sofa with integral cushion

ABSTRACT

AN ARTICLE OF FURNITURE WHICH MAY BE IN THE FORM OF A SOFA HAVING CUSHIONS CONSTRUCTED AS AN INTEGRAL PART THEREOF WITH EACH CUSHION INCLUDING A RIGID FRAMEWORK HAVING A PLURALITY OF ACRUATELY BOWED SEPENTINE SPRINGS WITH RESILIENT ADJUSTMENT STRAPS ATTACHED THERETO. THE END SPRINGS HAVE STABILIZING TIE CORDS AND INTERCONNECTING COIL SPRING ARE PROVIDED FOR STABILIZING THE ARCUATE SPRING MEMBERS.

Feb, 2, 1971 R. E. BURTON son WITH INTEGRAL CUSHION 5 Sheets-Sheet 1Filed April 17, 1969 Robert E Burton 1 N VEN TOR. Mm BY M m Feb. 2 1971R. E. BURTON SOFA WITH INTEGRAL CUSHION 3 Sheets-Sheet 2 Filed A ril 17,1969 Robert E Burton INVENTOR.

(ma M Em 2, 1971 R E, U T N SOFA WITH INTEGRAL CUSHION 3 Sheets-Sheet 5Filed April 17, 1969 Fig. 6

Robe/'2 E. Barron INVENTOR.

United States Patent 3,560,049 SOFA WITH INTEGRAL CUSHION Robert E.Burton, Coalinga, Calif. (464 Montgomery St., Orange, Calif. 92668)Filed Apr. 17, 1969, Ser. No. 816,925 Int. Cl. A47c 7/14, 7/02 US. Cl.297-452 8 Claims ABSTRACT OF THE DISCLOSURE The present inventiongenerally relates to furniture construction and more particularly a sofahaving integrally constructed cushion units which are fixedly secured tothe frame of the sofa.

In conventional sofa structures, the seat cushions are a completelyseparate unit from the frame and supporting spring assembly. Usually,the frame and supporting spring assembly are constructed and completelyupholstered and covered after which the cushion units which are alsoupholstered are placed in position. In the present invention, the springassembly is an integral part of the cushion and the sofa frame and isnot separately upholstered and is not a separate unit from the cushion.The cushion including the spring assembly slips into the framework ofthe sofa and is secured in place by screws or the like whichconstruction saves a substantial quantity of material and results in astronger and longer lasting product which can be produced at asubstantial saving in cost as compared with conventional sofas while atthe same time providing a structure which is attractive in appearanceand capable of construction in various styles.

An object of the present invention is to provide a sofa constructionemploying serpentine arcuately bowed sagless spring members secured attheir opposite ends to a rigid frame of the cushion together withtension adjustment straps interconnecting the spring and cushion framefor varying the firmness characteristics of the cushion unit andassuring that the arcuate bowed springs will return to their normalupwardly bowed position when weight has been removed from the cushionunit.

Another object of the present invention is to provide a sofa unit inwhich wrinkles in the upholstering material or cover is substantiallyeliminated inasmuch as the upholstering cover applies pressure on thesprings and the foam resilient material placed thereover and causes thearcuate springs to be pushed down slightly by the density of the foamresilient material which in return places tension on the resilienttensioning straps all of which coact to retain the upholstering cover ina smooth wrinkle-free condition.

Still another object of the present invention is to provide a sofaconstruction which is long lasting and durable, attractive in appearanceand requires substantially less labor and materials to construct.

These together with other objects and advantages which will becomesubsequently apparent reside in the details of construction andoperation as more fully hereinafter described and claimed, referencebeing had to the accompanying drawings forming a part hereof, whereinlike numerals refer to like parts throughout, and in which:

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FIG. 1 is a perspective view of a three cushion sofa unit with thecentral cushion unit removed;

FIG. 2 is a perspective view, with parts broken away and in section ofthe center cushion structure;

FIG. 3 is a transverse, sectional view of the sofa unit illustrating thecushion structure;

FIG. 4 is a longitudinal, sectional view taken substantially upon aplane passing along section line 44 of FIG. 3 illustrating furtherstructural details of the cushion unit;

FIG. 5 is a perspective view illustrating the construction of an endcushion unit; and

FIG. 6 is a vertical sectional view of the end portion of the sofaillustrating the relationship of the cushion unit thereto.

Referring now specifically to the drawings, a sofa incorporating thesignificant features of the present invention is generally designated byreference numeral 10 and includes a seat cushion frame structuregenerally designated by the numeral 12, end structures 14 and backreststructure 16. The seat cushion frame structure or assembly 12 includes alongitudinally extending front frame member or board 18 having the endsthereof interconnected by an end frame member or end board 20. Therearward ends of the end boards 20 are interconnected by a rear frame orboard 22 and another frame member 24 in the form of a wooden structuralelement interconnects the end members 20 in spaced relation to the rearframe member or board 22. This frame structure is supported in anysuitable manner such as by rear legs 26 and front casters 28 or the likewith the open lower end of the frame being closed by a fabric panel 30in a well-known and conventional manner. The specific supportingstructure and the bracing, corner blocks and the like all followaccepted practice in the construction of furniture items of this nature.

The backrest 16 is formed by end members 30, a top member 32, a frontframe member 34 and a lower frame member 36. Cushioning material or acushioning assembly 38 is mounted forwardly of the front frame 34 andthe cushioning material is covered by a fabric panel of upholsterymaterial 40 which extends downwardly and partially wraps around theframe member 36 and is secured thereto by a fastener 42 and extendsupwardly along the front of the cushioning material 38, across the toppanel 30 and then downwardly to close the rear of the backrest with thelower edge thereof being attached to the board 22. This specificconstruction also may be varied depending upon the appearancecharacteristics to be incorporated into the backrest.

The end structures 14 include a hollow frame including a bottom member44, an inner rigid panel 46, a top panel 48 and an interconnectingfabric panel 50 forming the outer surface of the hollow frame. Acushioning material is disposed against the inner, top and outer surfaceof the hollow frame as designated by the numeral 52 and an upholsteryfabric covering 54 is provided around the end frame structure asillustrated in FIG. 6 with the supporting legs 26 and the casters 28being in supporting engagement with the end frame members and if desiredor necessary, additional supporting legs and casters may be providedintermediate the ends of the sofa depending upon the over-all lengththereof.

The front board or frame member 18 is provided with cushioning material56 on the exterior surface thereof and the cushioning material iscovered with a fabric upholstery covering 58 which extends under thefront edge of the board 18 and is secured thereto in any suitable mannerand the upper edge of the fabric cover 58 extends over the rounded upperend of the front board 18 and is secured to the inner surface thereof inany suitable manner with suitable fasteners. The front fabric cover 58may be provided with a horizontal ribbing 60 or the like or 3 otherstructural features enhancing the decorative appearance thereof. Thus,an open framework is provided for receiving the seat cushion unit withone of the seat cushion units being omitted in FIG. 1 to show therelationship thereof to the sofa.

The center cushion unit is generally designated by the numeral 62 and isbest illustrated in FIGS. 2-4 and includes a rigid wood frame consistingof a pair of end members 64 and 66 interconnected by a lower frontmember 68 and an upper front member 70 as well as a rear lower member 72and an upper rear member 74 all of which may be wood frame members withthe members being interconnected by any suitable fastening construction,the details of which are not shown.

Extending between the front member 68 and the rear member 72 is aplurality of longitudinally spaced sagless spring members 76 ofgenerally serpentine construction with the front end of each spring 76being connected to a clip 78 which in turn is secured to the recessedforward surface 80 of the front frame member 68. The rear end of eachframe 76 is connected with a similar clip 82 secured in the recessedrear edge 84 of the rear frame member 72 with the clips 78 and 82 beingthat type of clip normally employed for securing the sagless springmembers in position with suitable fastening devices employed forsecurely mounting the springs so that they will be retained in upwardlybowed arcuate position as illustrated in FIG. 3.

Each forward end portion of each spring 76 has a tension strap 86connected to one of the loops thereof with the end of the resilientstrap 86 being secured to the top surface of the front top frame member70 by suitable fasteners 88. Similar resilient tensioning straps 90 areconnected to the rear end portion of each of the springs 76 and theterminal end thereof is anchored to the upper rear frame member 74 as byfasteners 92. Each end spring 76 is provided with a tie cOrd or twine 94which extends in a zig-zag manner between the loops of the end spring 76and the top surface of a recess 96 formed in the end frame members 64with the cord being secured thereto at spaced points by fasteners 98.For retaining the springs 76 in properly longitudinally spaced relation,a plurality of tension coil springs 100 are interconnected between theadjacent springs 76. Thus, the frame and spring assembly form a stablestructural assembly and overlying the springs is a resilient pad 102 offoam plastic or rubber having a fabric upholstery cover 104 thereon.Welting cords or ribs 106 may be provided for the pad or cushion anddepending upholstery panels 108 integral with the fabric cover 104extend downwardly along the end panels 64 and 66 andare secured to theupper surface of the cut-out area 96 or along the exterior surface ofthe end panels. Similar panels extend down from the front and rear withthe rear extension panel 110' extending under and being attached to thefront upper frame member 70. Thus, a unitary structure is formed whichis self-contained and thus may be inserted into the sofa framework 12with the front and rear frame members 68 and 72 being secured to thefront member 18 and the frame member 24 respectively by suitablefasteners 110 thus forming a rigid integral unit. As illustrated in FIG.4, the end members 64 and 66 are supported on front to rear supportmembers 112 extending between the front board member 18 and the framemember 24 thereby forming a rigid supporting unit with the centralcushion 62 integrally and fixed central portion fixed thereto.

The end cushion units are somewhat similar and are illustrated in FIGS.and 6 and generally designated by the numeral 114. The end cushion units114 each have four springs 76 rather than five and the inner end of thecushion unit is provided with the same type of end frame and tie cordassembly as employed in each of the center cushion. However, on theouter end of each end cushion unit 114, there is a solid end framemember 116 having a top member 118 attached thereto to which the tensioncoil springs 120 are connected and these springs extend between the endframe member 116 and the sagless springs 76 which are identical to thesagless springs illustrated in the center cushion unit 62. Other thanthis difference, the end cushion units and the center cushion unit arethe same and are secured in position in the same manner so that whencompleted, the cushion upholstery appears to provide three separate andindependent cushions but in actuality, the cushion units are fixedlysecured to the sofa frame and coact with the components of the sofaframe to further rigidify the unit.

The shape and configuration of the sofa unit may vary as may thedimensions of the various components including the strengthcharacteristics thereof. The integral cushion unit may also be used inother furniture items such as chairs or the like with the appearancecharacteristics being variable as desired. While the cushion unitprovides the appearance of a reversible cushion and affords the samecomfort characteristics, it additionally provides the sleekness andsoftness of foam rubber and resists wrinkling of the upholstery with theseams being retained in a straight condition. The juncture betweencushions have the same characteristics of softness and strength as thecentral part of each cushion. When employing this invention, wear will'be distributed equally on the springs and polyurethane foam as theweight of a person is applied to the cushion, it starts a chain ofevents. First, the arc spring begins to give and little by little,tension is put on the resilient straps which may be latex rubber or thelike until the latex rubber tension straps and are springs have built upeven tension against the speed and weight of a person and the springshave adjusted themselves. Now, the foam begins to give at theequalization of a person's weight to conform with the surface of theperson engaging the cushion. The chain of events works in reverse as aperson lifts himself off the cushion with the tension straps and thesprings returning to their normal position thus exerting pressureagainst the polyurethane foam and taking up the slack to keep wrinkleseliminated until the foam compresses itself into original density andshape.

The foregoing is considered as illustrative only of the principles ofthe invention. Further, since numerous modifications and changes willreadily occur to those skilled in the art, it is not desired to limitthe invention to the exact construction and operation shown anddescribed, and accordingly all suitable modifications and equivalentsmay be resorted to, falling within the scope of the invention.

What is claimed as new is as follows:

1. In an article of furniture, a cushion unit comprising an openperipheral frame including spaced parallel end members and spacedparallel side members, a plurality of longitudinally spaced arcuatelybowed sagless serpentine springs extending between the side members withthe arcuate central portion thereof extending above the upper edge ofthe frame, each of said springs including a tension strap havingresilient characteristics attached adjacent each end thereof andextending to and being attached to the frame at an elevation above thepoint of attachment of the springs thereby returning the arcuate springsto their arcuate positions when no load is applied thereto, and acushioning pad mounted in engagement with the springs and connected withthe frame to form a cushion unit capable of being inserted into anarticle of furniture and fixedly secured thereto.

2. The structure as defined in claim 1 wherein said tension straps arein the form of rubber straps, and a plurality of interconnecting springmembers extending longitudinally between the sagless springs to retainthem in spaced condition.

3. The structure as defined in claim 2 wherein at least one end memberhas the upper edge thereof recessed with the spring disposed above therecess, and a tie cord extending between the recessed upper edge of theend memher and the spring overlying the same for stabilizing the endspring and retaining it in position.

4. The structure as defined in claim 3 in which the other end member isalso recessed and provided with a tie cord associated with the spring inthe same manner.

5. The structure as defined in claim 3 wherein the other end memberdefining the frame is provided with a straight upper edge with the endspring adjacent thereto being spaced inwardly from the end member, andrelatively small coil springs extending between the end spring and theend member of the frame.

6. The structure as defined in claim 2 wherein said pad includes anupholstery covering thereon with depending panel extensions beingsecured to the frame thereby forming an assembled unit, said pad beingin the form of a foam plastic with the ends of the pad extendingslightly beyond the end members to cushion the entire surface of thecushion unit.

7. A sofa comprising a backrest, arm members and an open frame extendingbetween the arm rest and disposed forwardly of the backrest, and aplurality of assembled cushion units inserted into the open frame andmeans fixedly securing the cushion units thereto, each of said cushionunits including a rigid frame secured to the open frame forming part ofthe sofa, a plurality of springs mounted on the cushion frame and acushioning pad engaging the springs on the cushion frame and engagedwith the cushion frame for insertion into the sofa as a unit whereby thecushion units become integral with the sofa.

8. The structure as defined in claim 7 wherein each of the springs inthe cushion unit is in the form of an armately bowed serpentine springmember having the ends thereof anchored to the cushion frame, andresilient tension straps connecting the spring adjacent each end thereofto the frame at a point spaced above the point of connection between thesprings and frame for returning the springs to their arcuately bowedcondition.

References Cited UNITED STATES PATENTS 2,788,845 4/1957 Bond et a1267112 2,786,513 3/1957 Hoven et al. 297218 3,064,281 11/1962 Brown5353.7 3,165,308 1/1965 Ratbun 267111 C. A. NUNBERG, Primary ExaminerUS. Cl. X.R.

